Method of assembling knock-down cabinets



Jan. 2, 1962 E. RAWSON METHOD OF ASSEMBLING KNOCK-DOWN CABINETS Filed June 3, 1960 67mm Kabul/@07 4 llnired States The present invention relates to a method of assembling knock-down cabinets, and is particularly concerned with a method of making joints at the corners of knock down cabinets having highly finished surfaces.

The invention will be specifically described in connection with the assembly of cabinets for television receiving sets, but it will be understood that the method may be used in the assembly of any cabinet in which the walls are fabricated of non-metallic panels bonded to a metal plate.

Each wall of my improved cabinet comprises an outer panel of non-metallic material capable of taking a high polish, and an inner metal plate. The panel and plate are bonded together in any suitable manner and are then processed to make the unit into a wall member. The non-metallic panels will be hereinafter referred to as wood panels for convenience, but it will be understood that the term Wood is used generically and is intended to cover panels of plywood, hard pressed fiber board, or any other similar material capable of taking a hard finish. One example of a suitable material for the wood panel is the hard pressed fiber board sold commercially under the registered trade mark Masonite.

My improved method of fabricating the walls and assembling them into a cabinet provides a highly finished corner surface having a vein line spaced uniformly from the top edge of the cabinet. The vein line is formed by the outer edges of the metal plate to which the top wall panel is bonded, and is recessed slightly from the adjacent outer surface of the cabinet. The highly polished outer surface of the cabinet is uniform on all sides of the cabinet, and the recessed vein line makes the cabinet look exactly like cabinets made of solid wood walls.

The method of assembling the top and side walls of the cabinet will be described in detail in connection with the accompanying drawings showing the structure of the cabinet walls and also showing some of the apparatus used to fabricate the wall members and to assemble them into cabinets. In the drawings:

FIG. 1 is a perspective view of a cabinet assembled in accordance with the invention;

FIG. 2 is a front elevational view of one embodiment of an apparatus designed to trim both ends of the wood panel or the top wall member simultaneously;

FIG. 3 is an enlarged fragmentary front elevational view, showing one end of a top panel in position for the trimming operation;

FIG. 4 is an enlarged fragmentary front elevational View, showing one end of a top panel being trimmed;

FIG. 5 is a front elevational view of a side panel before it is trimmed;

FIG. 6 is a front elevational view, showing the side panel of FIG. 5 after it has been trimmed;

FIG. 7 is a perspective view of a top Wall with a portion of the wood panel broken away to show the metal plate to which it is bonded;

FIG. 8 is a perspective view of a side wall ready for assembly with the top wall of FIG. 7;

FIG. 9 is a fragmentary cross sectional view, showing the method of assembling the top and side walls; and

FIG. 10 is an enlarged fragmentary cross sectional view, showing a top wall and a side wall secured together in accordance with my invention.

Referring to the drawings, a television cabinet 2 comprises a top wall 3 and side walls 4. The present invention is concerned only with the method of securing walls 3 and 4 together, and the rest of the cabinet, comprising a bottom 5, a front 6, and a back (not shown), will not be specifically described. Both side walls 4 are identical, and therefore only one will be described, it being understood that the description of one applies equally well to the other.

The top wall 3 comprises a panel 7 of wood bonded to a metal plate 8 in any suitable manner. The metal plate is provided with integral apertured flanges 9 and ill at its front and back edges, respectively, for securing the front and back to the cabinet. The ends of flanges 9 and 16 are cut diagonally, as indicated at ll, for a purpose hereinafter disclosed. Threaded studs 12 are welded to one surface of the metal plate adjacent each end thereof. The purpose of these studs will be hereinafter described.

The opposite ends of the wood panel 7 extend beyond the corresponding ends of the metal plate 8, as indicated at 13, when the Wood panel and metal plate are bonded together. The bonding operation is conventional, and does not constitute part of the present invention, but it may be noted that the bonding operation is speeded up considerably because it is not necessary to register the wood panel with the metal plate accurately during the bonding operation. The top wall member, comprising the metal plate 8 and a wood panel 7 bonded thereto, is placed in a suitable fixture in which it is located by reference to the ends of the metal plate, and the ends of the wood panel are trimmed to provide an accurately dimensioned extension projecting beyond each end of the metal plate.

The apparatus shown in FIG. 2 comprises a pair of grinding Wheels 14 mounted in fixed laterally spaced relationship on standards 15 projecting upwardly from a base 16. The grinding wheels are powered in any suitable manner, as, for example, by driven belts 17. Two guide rails 18 are secured to the base 16, and a carriage T9 is slidably mounted on the guide rails. The carriage 19 comprises four or more angle members 29 having their lower edges shaped to fit on or in the guide rails 13, as indicated at 21. The angle members 24) are tied together by rods 22 and bars 23. Each angle member has a horizontal leg provided with an aperture adapted to receive one of the studs 12.

The top wall member, comprising a metal plate 8 and an untrimmed wood panel 7 bonded thereto, is positioned on the carriage 19 with four of the studs 12 extending through the apertures in the horizontal legs of angle members 20. The horizontal legs of the angle members support the top wall member in a plane perpendicular to the planes of rotation of the grinding wheels 1 The carriage 19 is then pushed forwardly, and both ends of the wood panel 7 are simultaneously trimmed to leave each end of the panel 7 extending an accurately dimensioned distance beyond each end of the metal plate 3.

It will be understood that the apparatus shown in FIG. 2 is merely exemplary, and any suitable apparatus may be provided for simultaneously trimming both ends of the wood panel. For example, the top wall member may be mounted on a stationary support, and the grinding wheels 14 may be movably mounted to swing or to slide into engagement with the ends of the wood panels to perform the trimming operation.

Each side comprises a wood panel 24 bonded to a metal plate 25. The metal plate 25 has flanges 26 and 27 extending perpendicularly from its upper and lower edges, respectively. The flange is provided with apertures 28 located to register with the studs 12 when the side Wall is assembled with a top Wall. The diameter of the apertures 28 is slightly greater than the diameter of the studs 12 to provide clearance therebetween. The flange 27 is provided with apertures 29 adapted to register with apertures 30 in the bottom 5. The front and back edges of the metal plate 25 are also provided with apertured flanges 31 for securing the front and back of the cabinet in place. The ends of flanges 26, 27, and 31 are each cut diagonally, as indicated at 11 in connection with flange 10. The upper edge of panel 24 projects beyond the upper edge of metal plate 25, as indicated at 32. The projecting portion 32 is trimmed or sanded to make the upper edge of the panel 24 flush with the outer surface of the flange 26.

After the panels 7 and 24 are trimmed to the proper size they are finished on each exposed surface in any suitable manner, preferably with a high polish, and are ready for the final assembly operations.

In the final assembly, the top wall 3 is positioned in any suitable frame, such as that indicated at 33, capable of holding the cabinet against any lateral movement without marring its finish. Preferably frame 33 engages all four edges of the top panel. The studs 12 extend upwardly in either a vertical or an inclined position. Each side wall 4 is then positioned against a side 'wall of the frame 33, with apertures 23 fitting over the studs 12. The larger diameter of the aperture 24"; permits any slight adjustment that may be required to make the side wall extend perpendicularly to the top wall of the cabinet. Clamps are provided inside the frame 33 for pressing the side walls and top wall into accurately assembled relationship. The clamps may be operated manually or pneumatically.

In the assembled position of the top and side walls the flanges 10 and 31 are coplanar. The diagonal edges 11 provide suflicient clearance between these flanges to prevent interference with the final assembly of the top and side walls. While the top and side walls are held in their final assembled positions by the clamps, metal strips (not shown) are rigidly secured across adjacent flanges '10 and 31 in any suitable manner to brace the corners of the frame.

When the top and side Walls are positioned for securement to each other, the metal plate 8 of the top wall extends between the upper edge of the .wood panel 24 of each side wall and the wood panel 7 of the top wall. The exposed edge of the metal plate 8, Which is recessed from the exposed surface of the side wall and from the end of the top wall, forms the vein line of the finished cabinet. Nuts 34 are applied to the studs 12 and are tightened against the flanges 26 to hold each side wall firmly to the top wall to form a rigid three wall structure. Variations in the thickness of the metal plate 8 or flanges "26 do not affect the final structure because the clearance provided by the apertures 28 relative to the studs 12 permits compensation for such variations when the nuts are tightened against the flange 26. The flanges 26 may be Welded to the metal plate 8, if desired, but the studs and nuts are preferred because they provide rigid connections at less cost.

It should be noted that my improved method of joining the top and side walls of a cabinet does not require matching any specific side wall with any specific top wall. Any side wall may be secured to any top wall,

and the finished cabinet will have an attractive corner joint With a neat, uniform vein line built right into the cabinet. My improved method of constructing the cabinet is adapted to mass production, and will provide every cabinet with the appearance of an individually built cabinet made of solid Wood walls.

After the top and side walls of the cabinet are joined together, the bottom may be secured to the lower edges of the side walls in any suitable manner, as, for example, by bolts 35 and coacting nuts 36. The front and back of the cabinet are assembled with therest of the cabinet after the television chassis is mounted on the bottom.

'Although I have described a preferred method of assembling the top and side walls of a cabinet in considerable detail, it will be understood that the description thereof is intended to be illustrative, rather than restrictive, as many details may be modified or changed Without departing from the spirit or scope of the invention. Accordingly, I do not desire to be restricted to the exact details disclosed.

I claim:

l. A method of making a corner joint for a knockdown cabinet that comprises the steps of bonding a Wood panel to a metal plate with opposite ends of the wood panel projecting beyond the ends of the metal plate, simultaneously trimming the ends of the wood panel to form a top wall having accurately dimensioned wood portions projecting beyond the ends of the metal plate, bonding a second wood panel to a flanged metal plate, trimming one end of the second wood panel flush with the outer surface of said flange to form a side wall, finishing the exposed surfaces of both of said Wood panels, assembling said walls with the outer surface of said flange abutting said metal plate and said side wall flush with one trimmed end of said top wall, and securing connecting means on said first metal plate and said flange together to hold said top and side walls in fixed relationship.

2. A method of making a corner joint for a knockdown cabinet that comprises welding a plurality of threaded studs to one surface of a metal plate, bonding a wood panel to the opposite surface of said metal plate, simultaneously trimming the ends of said wood panel to accurate spaced relationship to the adjacent ends of said metal plate to make a top wall, bonding a second wood panel to a second metal plate to make a side wall, said second metal plate having a flange extending perpendicularly to one end thereof and provided with apertures slightly larger than the diameter of said studs and spaced to conform to the spacing of saidstuds, trimming the adjacent end of said second wood panel flush with the outer surface of said flange, positioning said second wood panel perpendicular to said first wood panel with said studs projecting through said apertures, adjusting said second wood panel to align its outer surface with one end of said first wood panel, applying nuts to said studs, and tightening said nuts against said flange to secure said wall members together in said position.

References Cited in the file of this patent UNITED STATES PATENTS 21,274 Robertson Aug. 21, 1858 1,133,299 Lundin Mar. 30, 1915 FOREIGN PATENTS 104,975 Australia Aug. 30, 1938 

1. A METHOD OF MAKING A CORNER JOINT FOR A KNOCK DOWN CABINET THAT COMPRISES THE STEPS OF BONDING A WOOD PANEL TO A METAL PLATE WITH OPPOSITE ENDS OF THE WOOD PANEL PROJECTING BEYOND THE ENDS OF THE METAL PLATE, SIMULTANEOUSLY TRIMMING THE ENDS OF THE WOOD PANEL TO FORM A TOP WALL HAVING ACCURATELY DIMENSIONED WOOD PORTION PROJECTING BEYOND THE ENDS OF THE METAL PLATE, BONDING A SECOND WOOD PANEL TO A FLANGED METAL PLATE, TRIMMING ONE END OF THE SECOND WOOD PANEL FLUSH WITH THE OUTER SURFACE OF SAID FLANGE TO FORM A SIDE WALL, FINISHING THE EXPOSED SURFACES OF BOTH OF SAID WOOD PANEL, ASSEMBLING SAID WALLS WITH THE OUTER SURFACE OF SAID FLANGE ABUTTTING SAID METAL PLATE AND SAID SIDE WALL FLUSH WITH ONE TRIMMED END OF SAID TOP WALL, AND SECURING CONNECTING MEANS ON SAID FIRST METAL PLATE AND SAID FLANGE TOGETHER TO HOLD SAID TOP AND SIDE WALLS IN FIXED RELATIONSHIP. 